Hot-moldable copolymeric acrylonitrile compositions and molded products



resin in order to effect amaterial improvement in the toughness of the molded product. On the other hand, the acrylonitrile polymerization, product should not be used in a ratio, by weight, exceeding approximately 55 parts :thereof for each l5 parts of the heat-curable melamineformaldehyde resin, since otherwise the composition is lacking in the desired. molding and ouring characteristics, and the physical andelectrical properties or" the moldedproduct are materially impaired as compared with a product similarly made from an unmodified melamine-formaldehyde molding composition.-

at elevated temperatures, and hence during hot.

blending of the aerylonitrile polymerization product with the melamine-formaldehyde resin the former, which may be represented by R-CN where R represents the polymer residue, may undergo further polymerization through the nitrile groups to yield a polymer represented by which is more compatible or more easily dispensed inthe heatcurable melamine resin than the starting polymerization product.

In carrying our invention into efiect the thermoplastic copolymer of acrylonitrile is prepared in'accordance withmethods now well known to :thoseskilled in the art. In the preparation of the copolymers a mixture of monomers com- Good results are obtained with fhot-moldable compositions which are substantially homoge neous blends of ingredients comprising (1) a heat-curable melamine-formaldehyde resin and (2) a thermoplastic product of'polymerization of a polymerizable mass containing not less than about by weight thereof of acrylonitrile, the ingredientsof (1) and (2) being present in such compositions in the ratioof, by weight, from 50 to 85 parts of the former to from 50 to 15 parts of the latter. The thermoplastic polymerization product in our new compositions-imparts tough ness to the molded compositioncontaining-the melamine-formaldehyde resin which has been heat-blended with the-polymerization product and ultimately'curedin its presence during molding. During heat-blending of the melamineforinaldehyde resin and the polymerization product, or during molding of the resulting moldable composition, or during both such steps, it is possible that co reactionbetwe'en the aforementioned ingredients maytake place.

It was quite surprising and'unexpected that copolymers of acrylonitrile of the'kind described in the second paragraph of this specification could be compounded, as "by dry blending followed by hot milling, with a heat-curable melamine formaldeheyde resin in the presence or absence of fillers and other conventional components of molding compositions since such polymerization productaespecially those having a high content of combined acrylonitrileand a high molecular weight, are generally considered to be intractable materials that can be softened only at very high temperatures and pressures. Furthermore, such polymerization products, specifically those containing at least about 65% by weight thereof of acrylonitrile, are soluble in only a relatively-few solvents: Hence it-would not. be expected and could not be predicted that substantially "homogeneous compositions could be obtained by hot blending a polymerization product of the kind with which our invention is concerned and a heat-curable melamineformaldehyde resin. It isbelieved that these results are obtained because of the affinity between thenitrile '(-CN) groups in the acrylonitrile polymerization product and the triazine nucleus, which contains It isknown that the"-CN groups'in an acrylonitrile polymer undergo'polymerization reactions prising, by weight, at least about 25% and preferably not less than 40 or 50% of acrylonitrile is employed. 1'

Illustrative examples of monomers which may be copolymerized with acrylonitrile in proportions such as have been mentioned above to form a copolymer, more particularly a thermoplastic copolymer, are compounds containing a single CH2=C grouping, for instance the vinyl esters and especially the vinyl esters .of saturated aliphatic monocarboxylic acids, e. g., vinyl acetate, vinyl propionate, vinyl butyrate, etc.; vinylsubstituted. (monovinyl-substituted). aromatic compounds, for instance styrene and the various nuclearly substitutedstyrenes (e.-g., the various monoand dimethyl styrenes, the chloro, fluoro and other halogeno styrenes, the cyano styrenes, etc.) ,ia-,p-dimethyl styrene (isopropenyl toluene) and other a-SllbStitlltEd, nuclearly substituted styrenes, vinyl naphthalenes, ,vinyl pyridines, vinyl fluorenes, vinyl dibenzofurans, etc.; allyl, methallyl and other unsaturated; monohydric alcoholesters of monobasic acids, e. g., allyl and methallyl acetates, laurates, cyanides,. etc., methacrylonitrile, ethacrylonitrile and other hydrocarbon-substituted acrylonitriles; and numerous other 'vinyl, acrylic and other compounds containing a single CH2=C grouping-which are copolymerizable with .aorylonitrile to yield thermoplastic copolymers. Alkyl esters of alpha, beta-unsaturated polycarboxylic acids also may be copolymerized with acrylonitrile to yield copolymers which are suitable for use in modifying a heat-curable melamine-formaldehyde resin to'improve its useful properties, e. g., inproducing a hot-moldable composition. Examples of such esters are the dimethyl, -ethyl, -propyl, -isopropyl,'-butyl, etc.,-esters of maleic, fumaric, citraconic,1mesaconic, etc., acids.

. Any suitable method of polymerizingthemixture of monomers including acrylonitrile' may be employed. One suitable method is in an aqueous emulsion using a suitable polymerization catalyst, e. g., ammonium persulfate. Other polymerization methods, however, also may be employed, e. g., methods such as those described in Bauer et a1. U. S. Patent No. 2,160,054. The polymerization may be effected in the presence of a'plasticizer for thepolymerization product as disclosedand claimed in the copending application of Walter M. Thomas, Serial No. 780,309, now Patent No. 2,558,396 filed October 16, 1947. Thecopolymeric acrylonitrile may be of any suitable molecular weight, but ordinarily will be within the range of 15,000 to'300,000 or higher, as calculated from viscosity measurements using the 7 following test data were obtained on the molded specimens:

Izod impact strength it. lbs/in 0.328 Flexural strength lbs./sq. in 11,450 Mils flexing (mils flexed before breaking) 25 Dielectric strength at 233 C- volts/mill 400 Dielectric strength at 100 C do 327 Arc resistance seconds 160 Shrinkage mils per inch 2.7

Example 2 A copolymer of acrylonitrile and isopropenyl toluene was prepared by heating under reflux for 40 hours a mixture containing the following ingredients:

Parts Acrylonitrile 315.0 Isopropenyl toluene 285.0 Water 1520.0 Polyvinyl alcohol aqueous solution) 52.5 Hydrogen peroxide (30% aqueous solution) 6.3

- Parts Heat-curable melamine-formaldehyde resin 22.5 Acrylonitrile-isopropenyl toluene cop olymer 7.5 Calcined asbestos 45.0

The same procedure was followed as described under Example 1 with the exception that the time of milling on hot rolls maintained at 110 C. was 1% minutes. The molded pieces were hard, tough, substantially homogeneous and had a good surface appearance. The following test data were obtained on the molded articles:

Izod impact strength ft. lbs./in 0.333

Mils, flexing 22 Dielectric strength at 25.5 C volts/mil 389 Dielectric strength at 100 C do 328 Are resistance seconds- 150 Shrinkage mils per inch 2 Example 3 Same as Example 2 with the exception that polyacrylonitrile was used in place of the acrylonitrile-isopropenyl toluene copolymer, the milling time was 1 minutes and the temperature of -the rolls was 120C. since the polymer would not soften at a roll temperature of 110 0. Hard, tough, molded articles were obtained. The following test data were obtained on the molded pieces:

Izod impact strength ft. lbs./in 0.308

Flexural strength lbs./sq. in 9,980 Mils flexing. -1 21 Dielectric strength at 222 C volts/mil 412 Dielectric strength at 100 C do 398 Arc resistance "seconds" 150- Ezca'mple 4 Five parts of polyacrylonitrile in the form of melamine-formaldehyde resin and 1 part of zinc stearate (mold lubricant) were dry-blended together for about 30 minutes, and the blend was then heated on difierential rolls (60 mils clearance between the rolls) for minutes. The

slower roll was maintained at a temperature of ill anim'palpable powder, 95 parts of heat-curable I water.

Example 5 Same as Example 4 with the exception that 15 parts of a slightly coarser polyacrylonitrile and parts of the melamine-formaldehyde resin were used, and the dry blend was heated for 8 minutes on differential rolls, the slower one of which was maintained at about C. while the faster one was maintained at about 140 C. The clearance between the rolls was 60 mils. A molded specimen absorbed only 0.16% by weight of water when tested for water-absorption as described under Example 4. The flexibility of the molded pieces was slightly better than that of the products of Example 4.

Example 6 One hundred and twenty-two (122) parts ofslow to soften but gradually became continuous and leathery with a smooth surface grain; The sheet was removed from the rolls, and then broken and crushed to pass through a q -inch screen; The screened, plasticized polyacrylonitrile was dried in the oven at 85 C. for about 30 minutes, and was then used in making a molding composition as described below:

Parts Heat-curable melamine-formaldehyde resin 769 Succinonitrile-plasticized polyacrylonitrile 231 Zinc stearate 10 The aforementioned ingredients were dryblended together for about 30 minutes, and the, blend then was transferred to differential rolls, the slow roll being heated at about C. and the fast roll at about C. Milling on the rolls (60 mils clearance between the rolls) was continued for 10 minutes, after which the material was removed as a single sheet about 4-inch thick. The sheet was broken, crushed into granules and molded as described under Example, 4. The modulus of elasticity was only 0.89 as compared with 1.16 and 1.13 for that of molded articles of Examples 4 and 5, respectively.

Heat-curable melamine-formaldehyde resins also may be used as a binder for polymers and copolymers of acrylonitrile such as those hereinbefore mentioned when the latter are in the form of filaments, fibers, threads, yams. sheets, fabric (woven or matted): or other form. For instance, a laminated article was produced by v.b id w to e her. su erfi p sed a e s o afab i ':resi r 1,: 2.0 parts of 2B alcohol and 6.0' parts of --water. strips, 4 inches-bylBl/ inchesingsize,

of the polyacrylonitrile fabric material were immersed in the above solution, dried in air at room temperature and were then heated for 8 minutes at 115 C. Twenty parts of 50% aqueous alcohol was added to the impregnating solution, and the strips were re-dipped and re-dried as above described. The resulting strips were cut into pieces 4% by 4% inches in size. A laminated article, which contained about equal parts by weight of melamine-formaldehpde resin and polyacrylonitrile fabric, was formed by heating the crossed, superimposed layers of impregnated fabric for 50 minutes at 130 C. under a pressure of 1000 pounds per square inch. The laminate had a thickness of 0.052 inch and an excellent general appearance. It had a dielectric strength at 25 0., between -inch electrodes, of 570 volts per mil. The values for dielectric constant and dissipation factor, measured at different cycles and at room temperature, are shown below:

Dielectric Constant Dissipation Factor Other properties are shown below in compari son with those of other laminates similarly made from alpha-paper and canvas:

Polvacry- Alphacanvas lonitrile paper Laminate Laminate Lammate D stat flexural strength,

gs. per square cm 1, 800 l, 500 l, 460 Dynstat bending angle, de-

grees 49 7 8 Dynstat impact strength,

kgs. per sq. cm 228 13 15 Per cent of water absorbed after immersion in 0. water for 24 hours 0. 39 0. 84 0. 80

molding compositions containing no polymeric or copolymeric acrylonitrile modifier such as is used in practicing our invention. ,Also, they usually show less shrinkage when molded about inserts than moldings obtained from unmodified melamine-formaldehyde molding compositions.

.reB cau e, o t impro e n w h r ct ristics iQ 914 l -pecially- -adapted, for use gm ,the molding of intrit-moldablelcompositions, they are es- Qate-nart vThus-th ymay-bee ploy din mo ding lighting, fixtures,parts of ,e1ectrical appliances (including electrically insulating parts), bathroom and other household fixtures and ornamental objects,. etc. Theyalso may be used in forming surfacegsheets-jnpon plywood and other laminated articles, and as an overlay for other plastic and other structural materials.

The terms molding and moldable as used herein (including the claims) are employed in a broad sense and are intended to include within their meanings any means of forming orshaping the compositions to which the expressions apply including molding (in the more limited meaning of the word), calendering, extruding or any other means of forming the composition to a desired shape. Likewise, the term molded as used herein has a correspondingly broad meaning.

We claim:

1. A hot-moldable, substantially homogeneous composition comprising (1) a heat-curable melamine-formaldehyde resin and (2) a thermoplastic copolymer of copolymerizable ingredients including acrylonitrile and a monovinyl-substituted aromatic hydrocarbon, the acrylonitrile constituting at least about 25% by weight of the total copolymerizable ingredients used in forming the copolymer of (2), and the ingredients of 1) and (2) being present in the said composition in the ratio of, by weight, from about 45 to about 95 parts of the former to from about 55 to about 5 parts of the latter.

2. A composition as in claim 1 wherein the thermoplastic copolymer of (2) has a molecular weight within the range of about 15,000 to about 300,000.

3. A product comprising the molded composition of claim 1 and in which the melamineformaldehyde resin is in a cured state.

4. A composition which is moldable under heat and which is a substantially homogeneous blend of ingredients comprising (1) a filler, (2) a heatcurable melamine-formaldehyde resin, and (3) a thermoplastic copolymer of copolymerizable ingredients including acrylonitrile and a, monovinyl-substituted aromatic hydrocarbon, the acrylonitrile constituting at least about 25 by weight of the total copolymerizable ingredients used in forming the copolymer of (3), and the ingredients of (2) and (3) being present in the said composition in the ratio of, by weight, from about 45 to about 95 parts of the former to from about 55 to about 5 parts of the latter.

5. A composition as in claim 4 wherein the filler comprises asbestos.

6. A composition as in claim 4 wherein the monovinyl-substituted aromatic hydrocarbon ingredient of the copolymer of (3) is isopropenyl toluene.

7. A composition which is moldable under heat and which is a substantially homogeneous blend of ingredients comprising (1) a heat-curable melamine-formaldehyde resin and (2) a thermoplastic copolymer of copolymerizable ingredients including acrylonitrile and a monovinylsubstituted aromatic hydrocarbon, the acrylonitrile constituting at least about 50% by Weight of the total copolymerizable ingredients used in forming the copolymer of (2), and the ingredients of (l) and (2) being present in the said composition in the ratio of, by weight, from 50 to parts of the former to from 50* to 15 parts of the latter, the said thermoplastic copolymer of (2) REFERENCES CITED imparting toughness to the mmded composition The following references are of record in the 8. A product comprising the molded composifil of this patent;

tion of claim 7 and in which the melamine- 5 formaldehyde resin is in a cured state. UNITED STATES PATENTS Number Name Date EDWARD L. KROPA. 2,327,771 DAlelio Aug. 24, 1943 JOHN P. DUNNE. 2,463,032 Hanson Mar. 1, 1949 

1. A HOT-MOLDABLE, SUBSTANTIALLY HOMOGENEOUS COMPOSITION COMPRISING (1) A HEAT-CURABLE MELAMINE-FORMALDEHYDE RESIN AND (2) A THERMOPLASTIC COPOLYMER OF COPOLYMERIZABLE INGREDIENTS INCLUDING ACRYLONITRILE AND A MONOVINYL-SUBSTITUTED AROMATIC HYDROCARBON, THE ACRYLONITRILE CONSTITUTING AT LEAST ABOUT 25% BY WEIGHT OF THE TOTAL COPOLYMERIZABLE INGREDIENTS USED IN FORMING THE COPOLYMER OF (2), AND THE INGREDIENTS OF (1) AND (2) BEING PRESENT IN THE SAID COMPOSITIOR IN THE RATIO OF, BY WEIGHT, FROM ABOUT 45 TO ABOUT 95 PARTS OF THE FORMER TO FORM ABOUT 55 TO ABOUT 5 PARTS OF THE LATTER. 